Surgical stapler with firing lock mechanism

ABSTRACT

A surgical stapler is provided that maintains the jaws of the stapler in an open position and prevents firing of staples when a cartridge is not loaded in one of the jaws. Distinct positioning and sequencing of the jaws, capture pin and firing of the staples are provided by a latch mechanism. Such locking and latching mechanisms ensure proper operation of the stapler.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/796,503, entitled “SURGICAL STAPLER WITH FIRING LOCK MECHANISM” filedon Jun. 8, 2010, issued as U.S. Pat. No. 7,934,629, which is acontinuation of U.S. patent application Ser. No. 12/495,384, entitled“SURGICAL STAPLER WITH FIRING LOCK MECHANISM” filed on Jun. 30, 2009,issued as U.S. Pat. No. 7,731,073, which is a continuation of U.S.patent application Ser. No. 11/805,094, entitled “SURGICAL STAPLER WITHFIRING LOCK MECHANISM,” filed on May 21, 2007, issued as U.S. Pat. No.7,552,854, which claims the benefit of U.S. Provisional Application No.60/747,790, filed May 19, 2006, the disclosures of each of which arehereby incorporated by reference as if set forth in full herein.

BACKGROUND

The present invention relates generally to surgical occlusioninstruments and, more particularly, to surgical staplers.

Surgical staplers are used to approximate or clamp tissue and to staplethe clamped tissue together. As such, surgical staplers have mechanismsto ensure that tissue is properly positioned and captured prior todriving staples through the tissue. This partly entails that the clampedtissue together is compressed or squeezed to ensure that the width ofthe clamped tissue is not too large so as to prevent the staples fromforming against the anvil of the stapler as well as not too narrow as toeliminate capillary function in the clamped tissue. Mechanisms have alsobeen provided to ensure that staples are loaded in the stapler prior toclamping the tissue.

As a result, this has produced, for example, multiple triggers andhandles in conjunction with complex mechanism to provide proper staplingof the clamped tissue. With these complex mechanism, these mechanismincrease manufacturing burdens, introduces potential sources for devicefailure and confusion for the user. Thus, reliable stapling of clampedtissue without complex mechanisms is desired.

SUMMARY

Generally, a surgical stapler is provided. In one aspect, a surgicalstapler comprises a shaft, an actuator and a staple pusher. The shaftextends along a longitudinal axis having a proximal end and a distalend, a first jaw and a second jaw extending from the distal end of theshaft. The second jaw is arranged to receive a staple cartridge having aplurality of staples and is movable along the longitudinal axis towardsthe first jaw. The actuator is coupled to the proximal end of the shaft.The staple pusher is coupled to the actuator and is movable along thelongitudinal axis to push the plurality of staples out of the cartridgealong the longitudinal axis. The staple pusher has a distal portionpivotally connected to a proximal portion. The distal portion has afirst position and a second position with the first position preventingmovement of the staple pusher towards the first jaw.

In one aspect, a surgical stapler comprises a shaft, an actuator and astaple pusher. The shaft extends along a longitudinal axis having aproximal end and a distal end, a first jaw and a second jaw extendingfrom the distal end of the shaft. The second jaw is arranged to receivea staple cartridge having a plurality of staples and is movable towardsthe first jaw along the longitudinal axis. The actuator is coupled tothe proximal end of the shaft. The staple pusher is coupled to theactuator and is movable along the longitudinal axis to push theplurality of staples out of the cartridge along the longitudinal axis.The surgical stapler also comprises means for preventing longitudinalmovement of the staple pusher.

In one aspect, a stapler comprises a shaft and an actuator. The shafthas a distal end with a first jaw connected to an anvil, a movablesecond jaw arranged to receive a staple cartridge and a staple pushermovable within the second jaw. The second jaw is movable towards thefirst jaw in a longitudinal direction. The actuator is connected to aproximal end of the shaft and has a movable trigger connected to astationary handle housing. A firing lever is encased in the stationaryhandle housing and the firing lever has a hook operationally connectedto a projection extending from the staple pusher.

Many of the attendant features of the present invention will be morereadily appreciated as the same becomes better understood by referenceto the foregoing and following description and considered in connectionwith the accompanying drawings in which like reference symbols designatelike parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a surgical stapler in accordance withvarious aspects of the present invention;

FIG. 2A is a side view of a surgical stapler in accordance with variousaspects of the present invention;

FIG. 2B is a exploded view of a surgical stapler in accordance withvarious aspects of the present invention;

FIG. 2C is an enlarged perspective view of staple drivers in accordancewith various aspects of the present invention;

FIG. 2D is an enlarged top view of an anvil in accordance with variousaspects of the present invention;

FIG. 2E is an enlarged perspective view of an anvil in accordance withvarious aspects of the present invention;

FIGS. 3-12 are side views of a surgical stapler in accordance withvarious aspects of the present invention;

FIG. 13 is a perspective view of a surgical stapler in accordance withvarious aspects of the present invention;

FIGS. 14-15 are side views of a surgical stapler in accordance withvarious aspects of the present invention;

FIGS. 16-22 are side views of a surgical stapler in accordance withvarious aspects of the present invention;

FIGS. 23-26 are side views of a surgical stapler in accordance withvarious aspects of the present invention;

FIGS. 27-35 are side views of a surgical stapler in accordance withvarious aspects of the present invention; and

FIGS. 36-44 are side views of a surgical stapler in accordance withvarious aspects of the present invention.

DETAILED DESCRIPTION

In FIGS. 1-2, a surgical stapler has a barrel or shaft 8 extending alonga longitudinal axis with an actuator 9 connected to a proximal end ofthe shaft. End effectors or jaws 4,5 are integrally formed or extendfrom a distal end of the shaft 8. Disposed on jaws 4,5 are an anvil 2and a cartridge 6. In one aspect, the anvil 2 is disposed on jaw 4,which is stationary and is integrated with frame 10 of the shaft 8. Thecartridge support 3, part of jaw 5, is movable and is arranged toreceive the removable cartridge 6. The cartridge contains one or morestaples or fasteners and one or more staple drivers 17 such that whenpressure is applied to the staple drivers 17, the staples are ejected orfired from the cartridge 6 through tissue clamped or compressed betweenthe jaws 4,5. A staple pusher 14,15 provides or communicates thepressure to fire the staples. In one aspect, the staple drivers 12 hasat least one distal surface 12 a arranged to drive a staple out of thestaple cartridge and at least one proximal surface 12 b arranged tocontact the distal portion of the staple pusher 14,15. The distalportion of the staple pusher in one aspect has an enlarged end arrangedto contact the at least one proximal surface of the staple driver.

The shaft 8 comprises the staple pusher 14,15, the cartridge holder,retainer or support 3, frame 10 and a capture pin pusher 16. The frame10 is fixed to the actuator 9. The staple pusher 14,15, the cartridgesupport 3 and capture pin pusher 16 are movable relative to the frame 10and the actuator 9 traversing along a longitudinal axis of the surgicalstapler. In one aspect, the cartridge support comprises two symmetricalelongate shafts or slides connected together on a proximal end by asupport block case 31. The block case 31 in one aspect provides a hookor post from which a spring 91 is attached on one end and connected tothe actuator 9 on the other end. The spring biases the cartridge support3 via the block case proximally or away from the anvil 2 and towards theactuator 9. The distal end of cartridge support 3 defines an openingarranged to receive the cartridge 6 and in one aspect extends or spreadsorthogonally from the two side plates, slides or elongate shafts formingan enlarged “T” or “hammer head” like shape or profile.

The frame 10 defines a channel through which the cartridge support 3moves, e.g., slides longitudinally relative to the actuator 9. Thecartridge support 3 with the cartridge 6 moves longitudinally relativeto the actuator 9 to capture and clamp tissue between the cartridge andthe anvil 2. The cartridge support 3 in one aspect also defines achannel through which the staple pusher 14,15 and the capture pin pusher16 are disposed and movable therethrough. The staple pusher 14,15interacts with the cartridge 6 to eject staples from the cartridge 6 bycontacting staple drivers 17 within the cartridge 6. In one aspect, thestaple pusher 14,15 are attached to a spring 94 which is connected theactuator 9. The spring biases the staple pusher 14,15 proximally or awayfrom the anvil 2 and towards the actuator 9. The capture pin pusher 16also interacts with the cartridge 6 to cause a spring loaded capture pin18 situated in the cartridge 6 to extend into or allow retraction fromthe anvil 2.

The actuator 9 comprises a trigger 11 pivotably coupled to a stationaryhandle housing 19. The frame 10 in one aspect comprises an elongate bodyor shaft with one end, a proximal end, fixedly coupled to the actuator9. The other end of the elongate body of the frame 10 is generallyU-shaped with the anvil 2 attached to or extending along the frame on anaxis perpendicular to the longitudinal axis of the elongate body of theframe 10. In one aspect, the anvil is integral with the frame 10 forminga monolithic structure. The frame 10 in one aspect comprises symmetricalsupport blades both fixedly attached together on either end with one endcoupled to the actuator 9 and the other end coupled to or forming theanvil 2. Sufficient springs, pins, posts, spacers, slots, detents andother similar components or formations are also provided to securevarious components of the stapler together and to facilitate operationof the stapler.

In one aspect, the anvil 2 comprises a plurality of staple pocketshaving a generally hourglass shape with squared off ends 14 a. The widthof the middle or center portion 14 b is smaller than the width of theends 14 a to facilitate formation of staples driven against the staplepocket. The squared off ends providing a large first contact areadirecting the staple ends towards the narrow middle portion to form astaple. Two cavities are separated by the middle portion with a slopecurving up to the middle portion from each of the staple ends 14 a. Asloping surface 14 c slopes from the top surface of the anvil 2 andsurrounds a trough 14 d or pocket for receiving the legs of a staple.The staple is formed as the legs are deflected towards the centerportion 14 b of the trough. The trough is shallow and slopes downwardfrom the sloping surface 14 c but is somewhat raised at its center. Thestaple in one aspect is symmetrical, e.g., round or square. In oneaspect, the staples are flatten along one surface, e.g., the top and/or,along a symmetrically opposing surface, e.g., the bottom. Thecross-sectional shape of the staple or periphery is not fullysymmetrical, e.g., an oval versus a circle.

In one aspect, the cartridge 6 has a groove or elongate cavity thatmates and aligns with a corresponding projection or elongate raisedportion in the cartridge support 3 on the stapler. The projection andcavity combination identifies specific cartridge types, e.g., vascularversus non-vascular. The staple drivers or ejectors in the cartridge areprovided in three columns extending from a single contact base tosimultaneously eject all the staples in the cartridge to form against acorresponding three columns of staple pockets in the anvil.

In operation, a cartridge is loaded in the cartridge support 3 of thestapler. The stapler jaws 4,5 are positioned to place tissue between thejaws 4,5. If the loaded cartridge does not have staples, the trigger 11is not allowed to move or be actuated. Actuating the trigger 11, after astaple filled cartridge is loaded, causes the capture pin 18 to deployand the jaws 4,5 to move together. Thus, tissue becomes encased orencompassed between the jaws 4,5/frame 10 and the capture pin 18. Assuch, the tissue can be initially captured without placing significantpressure or force on the tissue from the jaws 4,5. Users, such as asurgeon, are thereby afforded the options of further fine tuning thepositioning of the stapler, leaving the stapler in place to performother surgical tasks, continue to operate the stapler or start over.Actuating the trigger 11 further causes the cartridge support 3 to movefurther towards the anvil 2 to partially close the jaws 4,5 and/or clamptissue. Completing the actuation stroke of the trigger 11 causes thejaws 4,5 to clamp or compress the tissue therebetween.

Unless the actuation stroke of the trigger 11 is completed, the surgicalstapler does not permit the firing of staples from the cartridge. Fromcapturing the tissue, partially closing and fully clamping the tissue,the user is provided multiple predetermined set points and positions toappropriately align and position the stapler jaws 4,5 relative to thetissue as desired. A release button 82 is provided, in one aspect, thatwhen actuated allows the stapler to be reset back to the initial ordefault position, i.e., jaws opened, as desired, to remove orre-position the location of the stapler. The second or subsequent fullor complete actuation stroke of the trigger 11 causes the staple pusher14,15 and staple driver 17 to move and eject the staples from thecartridge 6.

Referring also now to FIGS. 3-12, the predetermined or set positions ofthe cartridge support 3 relative to the anvil 2 are maintained by latch7. In one aspect, flat surfaces or edges of the latch 7 interact withslots or notches (e.g., first, second and third slots 52, 53, 54) in thecartridge support 3 to ensure that the cartridge support 3 moves oroperates in discrete predetermined positions. The latch in one aspect isgenerally u-shaped having flat surfaces with a generally square orrectangle cross-section. The positions in one aspect comprise open,capture, partially closed and closed positions. The sequential movementof the latch in each of the slots 52, 53, 54 ensures the properpositioning of the cartridge relative to the tissue and the anvil tooptimally allow the stapler to operate at each position removing therandom positioning of the cartridge relative to the anvil. For example,the closed position as predetermined by the latch and slot interactionensures the distance between the cartridge and the anvil is sufficientto effectively form and secure a staple through a tissue clamped therebetween. A firing lever 61 operatively engages the staple pusher 14,15to permit firing of the staples after the jaws are fully closed. In oneaspect, the firing lever is an elongate hook or partially curved orslanted elongate lever or anchor. After firing or ejecting the staplesfrom the cartridge, a handle fire lock lever 71 operatively engages thecartridge support 3 to prevent the trigger 11 from opening or movingproximally even if the trigger is released. In one aspect, the fire locklever 71 is a hook or partially curved or slanted lever or anchor.

In FIG. 3, the default or open position is shown with latch 7 positionedor riding along a top surface or edge of the cartridge support 3. Thetrigger 11 of actuator 9 is connected to a post, projection or pin 51that rests in a cavity or notch of the cartridge support 3, when thestapler is in an open, default, initial or resting position, i.e., thejaws are open to receive tissue there between. In the open position, thelatch 7 is not engaged or situated in one of slots 52, 53, 54 on thecartridge support 3. The latch 7 rests or is secured within a cavity orchannel disposed in the actuator 9, which restricts longitudinal orhorizontal movement of the latch, but allows vertical or perpendicularmovement of the latch.

The firing lever 61 is pivotally connected to the actuator 9 on one endand operatively connected to the staple pusher 14,15 on the other end.The other end or tip of the lever 61 moves somewhat freely and isdeflected downward or traverse to the longitudinal direction, i.e.,prevented from being in a horizontal or longitudinal position, when thejaws 4,5 are in the open position. The firing lever 61 is also coupledto the actuator 9 in one aspect by a spring 92 that biases the lever tothe longitudinal position and in a clockwise direction. The handle firelock lever 71 is also disposed within the actuator and is pivotallyconnected to the trigger 11 on one end. In one aspect, the fire locklever 71 is also coupled to the actuator by a spring 93 that biases thelever to a longitudinal or horizontal position and in a clockwisedirection. The fire lock lever 71 has a notch 73 arranged to receive aprojection, post or pin 55 connected to the cartridge support 3.

In placing the stapler in a capture configuration or position from theopen or initial position, the trigger 11 is pulled or actuated. Thecartridge support 3 (jaw 5) moves closer to the anvil 2 (jaw 4) via pin51 coupled to the trigger 11. The latch 7 is longitudinally fixed to theactuator 9 and thereby slides along the surface of the cartridge support3 as the cartridge support moves towards the anvil 2. After apredetermined distance is traversed, the latch 7 falls into or is biasedinto a slot 52 in the cartridge support 3. The engagement or interactionof the latch 7 with the cartridge support 3 causes the jaws and thus thecartridge and anvil to maintain the captured position. The capture pinpusher 16 and the corresponding capture pin 18 also move such that thecapture pin is deployed from the cartridge 6 into a cavity or opening inthe anvil 2. Further description of the capture pin and pusher isdescribed later below.

As the trigger 11 is further actuated, the latch 7 rides along theproximal sloped surface of slot 52 to be positioned into the slot 53.With the latch 7 in slot 53 of the cartridge support 3, the partiallyclosed position of the stapler is maintained, without furtherinteraction by the user, e.g., pressure or force is removed from thetrigger 11. In FIG. 4, the trigger 11 is pulled or actuated from thecapture position. The cartridge support 3 moves distally towards theanvil 2 via pin 51 coupled to the trigger 11 to close or move the jaws4,5 together, e.g., the jaw 5 with the loaded cartridge is moved closerto the jaw 4 as the cartridge support 3 moves distally. The cartridgesupport 3 is biased towards the proximal direction away from the anvil 2and thus resists the distal movement. The latch 7 rides along a surfaceof the cartridge support 3 as the cartridge support 3 slides by thelatch 7. The latch 7 moves into the slot 53 of the cartridge support 3such that the cartridge support 3 moves sufficiently distally topartially close the jaws 4,5. In other words, a predetermined distancebetween a starting point of the latch 7 to the slot 53 along thecartridge support 3 corresponds to a predetermined distance between thejaws 4,5 from the capture position to the partially closed position. Theengagement or abutment of the latch 7 with the distal edge of slot 53 inthe cartridge support 3 along with the interaction of the spring 91biasing the cartridge support in the proximal direction traps or fixesthe cartridge support in position to allow the jaws 4,5 and thus thecartridge and anvil to maintain a partially closed position. The firinglever 61 remains deflected. In the partially closed position, thecartridge support 3 is moved distally and thus the pin 55 is also moveddistally but does not yet contact or is received by the fire lock lever71.

The staple pusher 14,15 is coupled to the cartridge support 3 and assuch moves as the cartridge support 3 moves. Also, in one aspect, thepin 51 coupled to trigger 11 is operatively coupled to the staple pusher14,15. The staple pusher 14,15 is further coupled to the latch 7 and inone aspect biased by a spring 91 coupled to the actuator 9 on one endand connected to the proximal end 62 of the staple pusher. The spring 91biases the staple pusher in a proximal direction or away from the anvil2. In one aspect, the staple pusher 14,15 has the same or less number ofslots than the cartridge support 3. The slots in the staple pusher 14,15are similar in size and shape to the slots in the cartridge support 3.Thus, as the trigger 11 is actuated, the staple pusher 14,15 moves andfollows the movement of the cartridge support 3. Likewise, as the latch7 maintains the position of the cartridge support 3, the position of thestaple pusher 14,15 is also maintained via slots in the staple pusher orin one aspect the connection to the cartridge support 3.

In FIG. 5, the trigger 11 is fully actuated or pulled, e.g., a full orcomplete actuation stroke, and as such the cartridge support 3 is moveddistally via pin 51 to close or move the jaws 4,5 together. The latch 7rides along the proximal sloped surface of the slot 53 and then movesinto the slot 54 as the cartridge support 3 moves sufficiently distal oralong a predetermined distance to fully close the jaws 4,5. Theengagement or abutment of the edge or surfaces of latch 7 with thedistal edge of slot 54 in the cartridge support 3 along with theinteraction of the spring 91 biasing the cartridge support 3 in theproximal direction maintains the cartridge support in position therebymaintaining the jaws 4,5, the cartridge and anvil, in a closed orclamped position.

The firing lever 61 becomes unobstructed and thus moves to a horizontalposition or aligns longitudinally with the cartridge support 3. In oneaspect, pin 51 moves and thus the firing lever is unobstructed. Biasedby spring 92, the firing lever pivots into longitudinal alignment withthe cartridge support 3. As shown, the firing lever 61 has a hook ornotch 63 arranged to operatively receive pin 51 connected to the trigger11. The pin 55 moved further distally as the trigger moves engages orcontacts the fire lock lever 71 deflecting the lever 71.

The trigger 11 is released as shown in FIG. 6, but the engagement of thelatch 7 with the slot 54 in the cartridge support 3 continues tomaintain the jaws 4,5 in the closed position. With the trigger released,the trigger pivots being biased by spring 11 a. The pin 51 coupled tothe trigger travels back proximally riding over a distal sloped surface63 b of the firing lever 61 and deflecting the firing lever 61. Thefiring lever 61 returns back to a horizontal or longitudinally alignedposition once the pin 51 moves back sufficiently in the proximaldirection, clearing the slanted, sloped or ramped surface or hookportion of the firing lever 61. The pin 55 coupled to the cartridgesupport 3 remains stationary and continues to contact and deflect thefire lock lever 71.

FIG. 7 shows the stapler in position to fire or eject the staples fromthe cartridge 6. The jaws 4,5 remain in the closed position. The pin 51continues to travel back proximally along the firing lever 61 with thefiring lever remaining in a horizontal or longitudinal position. The pin55 remains stationary. The fire lock lever 71 moves in the proximaldirection and pivots upon clearing the pin 55 allowing the fire locklever 71 to move to a horizontal position.

In FIG. 8, the stapler has fired or ejected the staples from thecartridge through the clamped tissue. The trigger 11 is fully closed,pulled or actuated. The engagement or contact of the surfaces or edgesof latch 7 with the surfaces or edges of slot 54 in the cartridgesupport 3 along with the bias or force provided by the spring 91continues to maintain the jaws in the closed position. In firing,actuating a firing stroke, the pin 51 connected to the trigger 11 movesdistally to engage the notch 63 of the firing lever 61. The firing lever61 connected to the staple pusher 14,15 causes the staple pusher to alsomove distally. As such, the staple pusher contacts and moves the stapledrivers within the cartridge 6 subsequently ejecting the staples withinthe cartridge, and thus stapling the tissue clamped between the jaws4,5.

The staple pusher 14,15 is coupled to the cartridge support 3 and assuch moves as the cartridge support 3 moves. However, in one aspect, thestaple pusher 14,15 has one less slot than the cartridge support 3,e.g., the staple pusher 14,15 does not have a slot that corresponds tothe slot 54 on the cartridge support 3. In one aspect, the slot on thestaple pusher 14,15 that corresponds to the slot 54 on the cartridgesupport is larger than the slot 54 in the cartridge support 3.

As such, the latch 7 maintains the position of the cartridge support 3and the staple pusher 14,15, but the staple pusher 14,15 is allowed tomove distally or towards the anvil 2. Thus, in firing, as the trigger 11is actuated, the staple pusher 14,15 moves while the cartridge support 3remains stationary. Also, with fewer components moving and less biasingforces tending towards the proximal direction, a tactile feedback isprovided to the user indicating firing of the staples versus moving thecartridge or capturing/clamping the tissue.

The pin 55 remains stationary or fixed. In firing, the fire lock lever71 connected to the trigger 11 moves distally to cause the lever 71 topivot and engage the pin 55 to engage or rest within the notch 73 of thefire lock lever 71. The engagement of the fire lock lever 71 with thestationary pin 55, i.e., the pulling force of the fire lock lever 71towards the proximal direction on the pin 55, prevents the trigger 11from moving back distally or opening, even if the trigger is released.The locked or fixed trigger adjacent to the handle of the actuator 9provides a visual feedback that the stapler has been fired, i.e.,staples ejected.

The stapler can be reset during or after the operation of the stapler.For example, upon actuation of a release button 82, the stapler is resetor moved to its original or initial open position as the jaws 4,5 moveapart or open. As shown in FIGS. 9-12, the latch 7 is lifted or movedout of engagement with the slot 54 in the cartridge support 3, whichallows the cartridge support 3 to retract proximally. The latch 7 isconnected to a release latch or arms 80 that is coupled to a releasebutton 82 on the actuator 9 (FIGS. 13-14). In one aspect, with thebutton 82 actuated or pressed, arms 81 of the release latch 80 pivot andlift or move the latch 7 out of engagement with the cartridge support 3.The button 82 in one aspect is biased away from the actuator by a leafspring 95 coupled to the actuator. In one aspect, the release arms 80and latch 7 are biased to engage the cartridge support 3 by acompression spring 96 coupled to the actuator 9.

The firing lever 61 remains in the horizontal position, but iseventually deflected as shown in FIGS. 9-10. With the cartridge support3 retracting, being urged by spring 91, the pin 55 also starts to or isallowed to move proximally causing the fire lock lever 71 to start topivot. Also, with the pin 55 moving, the engagement of the fire locklever 71 with the pin 55 starts to be released. Fire lock lever 71 andpin 55 typically interact to prevent the trigger from moving backdistally or opening, even if the trigger is released. However, with thefire lock lever 71 disengaged from pin 55 the trigger is now allowed toopen. The cartridge support 3 retracting also engages pin 51 to furthercause the trigger to open (FIG. 11). FIG. 12 shows the stapler movedback to the original default or initial open position.

FIGS. 15A-D show an actuator 9 in accordance with various aspects of thepresent invention. The trigger 11 of the actuator 9 is used to advancethe cartridge and fire staples from the cartridge 6. A release button 82is also coupled to the actuator and is configured to reset the staplerback to its initial opened position at any time throughout operation ofthe stapler. As the trigger 11 is first actuated, the cartridge support3 with the cartridge 6 and the staple member or pusher 14,15 advancetowards the anvil 2. When the trigger 11 is fully actuated, thecartridge 6 is positioned at a specific distance to form staples againstthe anvil 2. Also, after the trigger 11 is released, the trigger engagesthe firing lever 61′. When the trigger 11 is actuated again, the firinglever connected the staple pusher 14,15 advances to eject the staplesfrom the cartridge 6.

As previously noted, actuating the release button 82 can occurthroughout the operation of the stapler. For example, as the stapler isready to fire staples, e.g., after the first actuation of the trigger,the release button can be actuated. Since the firing lever 61′ isalready engaged or capable of being engaged by the trigger 11, a biasingmechanism 61 a is provided to ensure that the firing lever is disengagedby the trigger irrespective of movement of the cartridge supports orstaple or firing pusher 14,15. A protrusion or tab, in one aspect,provides the biasing mechanism. The tab extends from the firing lever61′ to ensure engagement with the release latch or arms 80 coupled tothe release button 82 to bias the firing lever 61′ directly when therelease button is actuated. As such, activation of the button moves therelease arms 80 that contact the tab 61 a from the firing lever 61′disengaging the firing lever from pin 50.

In one aspect, a lockout mechanism is provided to prevent re-firing of aspent staple cartridge and re-clamping of tissue through interactionwith a firing member and the disposable staple cartridge. Referring toFIG. 16, the stapler is shown without a loaded disposable cartridge 6.In this state, the staple pusher 14,15 pivots upward due to a biasingmember 41, e.g., a spring, located in the frame of the stapler. Thestaple pusher in one aspect comprises a two-piece elongate structure, aproximal portion 14 and a distal portion 15. The proximal and distalportions of the staple pusher are connected at a mating connection orhooks 42. The mating hooks 42 allows the distal portion 15 of the staplepusher being biased by the spring 41 to pivot relative to the proximalportion 14 of the staple pusher. A projection, post or pin 52 disposedon the cartridge support 3 extends across a channel formed between thecartridge support 3 through which the staple pusher slides. The pin 52extends through a generally L-shaped slot 43 in the staple pusher 15.The pin 52 attached or otherwise connected to the cartridge support 3moves with the cartridge support 3. The engagement of pin 52 with thebottom or L-portion of the L-shaped slot prevents the staple pusher14,15 from being moved towards the anvil 2. With the staple pusher beingimmobilized or otherwise prevented from moving, the cartridge support 3movements are also restricted. Operationally, from the default initialopen position to the closed or clamped position, the staple pusher 14,15and cartridge support 3 movements are coupled to each other. As such,movement of the trigger 11 of actuator 9 causes movement of both thestaple pusher 14,15 and cartridge support 3 away from the actuator 9toward the anvil 2. The engagement of the pin 52 with the bottom portionof the L-shaped slot 43 in the staple pusher 14,15 also limits thedistance or movement of the staple pusher being biased out of thestapler by spring 41.

In FIG. 17A-B, the stapler is in an open or initial position and loadedwith a staple filled or loaded cartridge 6. The staple driver(s) 17disposed or included with the cartridge 6 that facilitate ejection orfiring of the staples from the cartridge when contacted by the staplepusher 14,15. A portion of the staple driver(s), e.g., projection 70,engages the distal portion of the staple pusher deflecting or biasingthe staple pusher downward against or counteracting the force of spring41. This deflection also moves the bottom portion of the L-shaped slot43 in staple pusher 14 substantially out of contact with pin 52. Thus,the staple pusher becomes unobstructed and free to move.

The stapler, in FIG. 18, is in the next stage of actuation or in thecapture position with the capture pin advanced and the cartridge 6 movedtowards the anvil 2. FIG. 19 shows the stapler being partially closedand FIG. 20 shows the stapler closed (tissue clamped). FIG. 21 shows thestaples fired from the cartridge 6.

FIG. 22 shows the stapler opened or reset to allow removal of thestapler from the operation site or tissue. With the staple drivers 17and thus projection 70 in their most distal position in the cartridge 6,the staple pusher 14,15 is permitted to pivot upward due to spring 41.Thus, the pin 52 engages the bottom portion of the L-shaped slot in thestaple pusher 15, which prevents further distal movement of the staplepusher 14,15 and also cartridge support 3. Hence, re-firing of a spentor empty staple cartridge and re-clamping of tissue, i.e., preventingjaw closure, are prevented until a loaded cartridge is inserted betweenthe cartridge support.

As previously described and shown in the preceding figures, the capturepin 18 within cartridge 6 is operatively connected to the capture pinpusher or driver 16. In one aspect, as shown in FIG. 23, the capture pinpusher 16 has a slot 35 on one end, e.g., the proximal end, in which apin or post extending from a pivot lever 34 connects the pivot lever 34to the capture pin pusher 16. In the default or open position, a pin,detent or post 37 extending from the other end of the pivot lever 34 isoperatively coupled to the cartridge support 3 via a slot 36 in thecartridge support 3. As shown in FIG. 23, the pin 37 extends from thelever and rests in the slot 36.

Movement of the trigger 11 of the actuator 9 causes the cartridgesupport 3 to move longitudinally as post 51 is moved by trigger 11. Withthe cartridge support 3 moving, the slot 36 in the cartridge support 3interacts with the pin 37 of lever 34 causing the lever 34 to pivot in acounter-clockwise direction. Continued movement of lever 34 causes pin37 to move out of the slot 36 (FIG. 24). The counter-clockwise motion ofthe lever 34 causes the capture pin pusher 16 via the interaction withthe pin from lever 34 with the slot 35 in the capture pin pusher 16 toadvance or move longitudinally, which in turn extends the capture pin 18into the anvil 2 of jaw 4 capturing tissue within the space defined bythe jaws/frame and capture pin. As shown in FIG. 25, the pin 37 ridesalong a surface of the cartridge support 3 as the cartridge support 3 isadvanced distally to partially close the jaws. In and to the closed orclamped position of the stapler, as shown in FIG. 26, the pin 37continues to slide along the surface of the cartridge support 3.

In FIG. 27, the stapler is in the open or initial position with a loadedcartridge, i.e., a cartridge having staples. In this position, the jaw 5is allowed to move freely and staples may be fired. A lever 21 ispivotally connected to the cartridge support 3 via a rivet, pin or post22. The lever 21 has a tip 23 that contacts a portion of the stapledrivers or a protrusion 26 extending from the staple drivers to maintaina substantially horizontal position. The other end of the lever 21 has apin 24 extending through an aperture 25 within the frame 10. The pin 24slides along the aperture 25 as the cartridge support 3 is moved.Trigger 11 of actuator 9 is in an open position.

FIGS. 28A-B show the pin 24 sliding along the aperture 25 slightly andthe lever 21 and tip 23 remaining substantially horizontal as thecapture pin 31 driven by capture pin pusher 33 is extended into theanvil. Trigger 11 of actuator 9 and the jaws 4,5 are moved to a captureposition. FIGS. 29A-B show the pin 24 continuing to slide along theaperture 25 and the lever 21 and tip 23 remaining substantiallyhorizontal as the stapler continues to close. Trigger 11 of actuator 9and the jaws 4,5 are moved to a partially closed position. FIGS. 30A-Bshow the pin 24 slide into the end of the aperture 25 and the lever 21and tip 23 remaining substantially horizontal as the stapler is closed,clamping tissue between the jaws. Trigger 11 of actuator 9 and the jaws4,5 are moved to a closed position.

FIG. 31 shows that the pin 24, lever 21 and tip 23 remain in the sameposition as the stapler is prepared to fire staples and the trigger 11is moved back to an open position. FIGS. 32A-B show the pin 24, lever 21and tip 23 remain in the same position as the stapler is fired andstaples are ejected from the cartridge 6 with the trigger 11 moved backto a closed position. In this position, the protrusion 26 extending fromthe staple drivers moves with the staple drivers as the staples arefired and thus no longer contacts the tip 23 of lever 21. Thus, theaperture 25 within frame 10 contacting pin 24 maintains the lever 21 ina substantially horizontal position.

After firing, the stapler is reset in which the capture pin 31 and jaws4,5 retract. As the cartridge support 3 retracts, the pin 24 slidesalong the aperture 25 until it reaches the proximal end of the aperture25 where it is allowed to pivot. FIGS. 33A-B show the lever 21 pivoted,i.e., no longer in a horizontal position, with pin 24 moved in a lowerpart of an L-shaped portion of the aperture 25 of the cartridge support3. The contact of pin 24 with the aperture 25 prevents longitudinalmovement of the cartridge support even if the trigger 11 is actuated.

As shown in FIG. 34, when a loaded cartridge is inserted into thecartridge support 3, the protrusion 26 contacts tip 23 of lever 21 tocausing the lever 21 to rotate and pin 24 to move out of the lower partof the aperture 25 placing lever 21 in a horizontal position (FIG. 35).In this position, the jaw 5 is allowed to move freely and staples withinthe cartridge 6 may be fired.

In FIG. 36, the stapler is in the open or initial position with acartridge 6 being loaded into the stapler. In this position, the jaw 5is not allowed to move freely and staples may not be fired. A pivotallyconnected lever 61 is connected to the cartridge support 3 via a rivet,pin or post 68. Without a cartridge loaded into the stapler, the lever61 prevents movement of the jaws 5. A pin 64 extends from one end of thelever 61. The pin 64 extends through an aperture 65 of the cartridgesupport 3 and rests in a slot 66 of frame 10. As such, the pin 64interacting with the cartridge support 3 and frame 10 preventsapproximation of the jaw 5. In FIGS. 37-39, with a cartridge beingloaded into the stapler, tip 63 of the lever 61 contacts a portion orprotrusion (not shown) of the staple drivers or cartridge 6 causingrotation of the lever 61. As such, the pin 64 slides along the aperture65 and out of the slot 66 of frame 10.

In FIGS. 40-41, the position of lever 61 is maintained as the capture orcapture pin 31 is extended into the anvil. Likewise, as trigger 11 ofactuator 9 and the jaws 4,5 are respectively moved to a capture positionand subsequently to a closed position, the lever's position remainsunchanged. Referring now to FIG. 42, as trigger 11 is manipulated tofire the stapler, the staple pusher 15 moves distally to push or drivethe staples out of the cartridge 6. A projection or detent 67 extendingfrom the staple pusher engages the lever 61 causing the lever 61 topivot away from the staple pusher. Spring (not shown) assists in thepivoting of the lever, for example, by biasing the lever 61 in aclock-wise direction. The pin 64 slides along the aperture 65 until itcontacts the frame preventing further rotation of the lever 61. As such,the lever 61 is generally parallel with the longitudinal axis of thestaple and the frame 10.

Referring now to FIGS. 43-44, after firing, the stapler is reset inwhich the capture pin 31 and jaws 4,5 retract. As the cartridge support3 retracts, the pin 64 slides along the frame 10 until it reaches theslot 66 in which the lever 61 is then allowed to pivot back to itsinitial position. Pin 64 also slides along the aperture 65 until itreaches the end of the aperture 65. Pin 64 contacting the slot 66 in theframe prevents longitudinal movement of the cartridge support even ifthe trigger 11 is again actuated.

Accordingly, the present invention provides a surgical stapler. Althoughthis invention has been described in certain specific embodiments, manyadditional modifications and variations would be apparent to thoseskilled in the art. It is therefore to be understood that this inventionmay be practiced otherwise than specifically described, includingvarious changes in the size, shape and materials, without departing fromthe scope and spirit of the present invention. Thus, embodiments of thepresent invention should be considered in all respects as illustrativeand not restrictive, the scope of the present invention to be determinedby the appended claims and their equivalents rather than the foregoingdescription.

1. A stapler comprising: an actuator comprising: a stationary handlehousing; and a trigger pivotably coupled to the stationary handlehousing; a shaft extending along a longitudinal axis and having aproximal end with the actuator connected thereto, and a distal end, theshaft comprising: a staple pusher movable through the shaft along thelongitudinal axis; and a capture pin pusher movable through the shaftalong the longitudinal axis, the staple pusher and the capture pinpusher sequentially actuatable by pivoting of the trigger relative tothe stationary handle housing of the actuator; a jaw assembly positionedat the distal end of the shaft, the jaw assembly comprising: a first jawdefined by a stationary anvil extending from the distal end of the shaftand integrated with the shaft; a second jaw defined by a cartridgesupport; and wherein the second jaw is movable along the longitudinalaxis from an open position spaced apart from the first jaw towards thefirst jaw to a closed position wherein the second jaw is positioned apredetermined distance from the first jaw; and a staple cartridgepositionable on the cartridge support, the staple cartridge comprising:a plurality of staples; a staple driver having a distal surface arrangedto drive the plurality of staples out of the staple cartridge and aproximal surface arranged to contact the staple pusher of the actuator;and a capture pin arranged to contact the capture pin pusher of theactuator.
 2. The stapler of claim 1, wherein the staple pusher comprisesa two-piece elongate member having a proximal portion and a distalportion.
 3. The stapler of claim 2, wherein the proximal portion and thedistal portion of the staple pusher are connected at a matingconnection.
 4. The stapler of claim 3, wherein the mating connectioncomprises mating hooks pivotably joining the proximal portion and thedistal portion such that the distal portion can be selectively pivotedinto an immobile position in which the staple pusher is prevented frommoving relative to the shaft.
 5. The stapler of claim 1, furthercomprising a latch mechanism defining a plurality of predeterminedpositions of the first jaw and the second jaw.
 6. The stapler of claim5, wherein the latch mechanism defines the open position, a captureposition, and the closed position.
 7. The stapler of claim 6, wherein afirst actuation stroke of the trigger advances the second jaw to thecapture position, and wherein a second actuation stroke of the triggeradvances the second jaw to the closed position.
 8. The stapler of claim1, wherein the plurality of staples are ejected from the staplecartridge upon a second full actuation stroke of the trigger.
 9. Astapler comprising a handle assembly comprising: a stationary handle;and a trigger pivotably coupled to the stationary handle; a shaftextending along a longitudinal axis and having a proximal end with thehandle assembly connected thereto, and a distal end; a jaw assemblypositioned at the distal end of the shaft, the jaw assembly comprising:a stationary anvil extending from the distal end of the shaft andintegrated with the shaft; a cartridge support arranged to receive astaple cartridge; and wherein the cartridge support is actuatable bypivotal movement of the trigger relative to the stationary handle andthe cartridge support is movable along the longitudinal axis; and alatch mechanism configured to maintain the jaw assembly in one of aplurality of predetermined positions of the cartridge support relativeto the anvil, the predetermined positions comprising an open position inwhich the anvil is spaced apart from the cartridge support and a closedposition wherein the second jaw is positioned a predetermined distancefrom the first jaw.
 10. The stapler of claim 9, wherein thepredetermined positions further comprise a capture position in which theanvil and the cartridge support are spaced in a predetermined distanceto capture tissue therebetween.
 11. The stapler of claim 10, wherein thelatch mechanism is sequentially positionable from the open position tothe capture position and from the capture position to the closedposition responsive to pivotal movement of the trigger relative to thestationary handle.
 12. The stapler of claim 9, wherein the latchmechanism comprises: a plurality of notches formed in the cartridgesupport, each one of the plurality of notches corresponding to one ofthe predetermined positions; and a latch sequentially engageable in oneof the plurality of notches to maintain the jaw assembly in thecorresponding one of the predetermined positions of the cartridgesupport relative to the anvil.
 13. The stapler of claim 12, wherein atleast one of the plurality of notches comprises a sloped surfaceallowing longitudinal advancement of the latch over the sloped surfaceand an edge opposite the sloped surface preventing retraction of thelatch over the edge to define a predetermined position of the cartridgesupport relative to the anvil.
 14. The stapler of claim 12, furthercomprising a release mechanism to selectively disengage the latch fromone of the plurality of notches.
 15. The stapler of claim 9, furthercomprising a release mechanism to release the latch mechanism.
 16. Astaple cartridge for a surgical stapler, the staple cartridgecomprising: a plurality of staples; a staple driver having a distalsurface arranged to drive the plurality of staples out of the staplecartridge and a proximal surface opposite the distal surface; and aspring-loaded capture pin, wherein the staple cartridge is positionableon a cartridge support of the surgical stapler having a sequentiallylongitudinally advanceable capture pin pusher and staple pusher suchthat the proximal surface of the staple driver contacts the staplepusher and the capture pin is operatively connected to the capture pinpusher; and wherein the staple driver comprises a projection adapted toengage the staple pusher of the stapler to permit movement of the staplepusher in the stapler, the projection sized and configured to disengagefrom the staple pusher upon firing of the plurality of staples from thestaple cartridge of the stapler to obstruct movement of the staplepusher in the stapler.